Application of advanced laser consolidation process for the manufacturing of Complex FSP shells


  1. Xue, L.
  2. Theriault, A.
  3. Islam, M.U.
  4. Purcell, C.J.
Corporate Authors
Integrated Manufacturing Technologies Inst, London ONT (CAN);Defence Research Establishment Atlantic, Dartmouth NS (CAN)
The Integrated Manufacturing Technologies Institute (IMTI) of NRC has devloped a novel process called "Free-From Laser Consolidation" that produces functional net-shape components layer by layer directly from CAD models by using a laser beam to melt and re-solidify the injected powder (or wire). As opposed to conventional machining processes, this computer-aided manufacturing (CAM) technology can build complete parts or features on an existing component by adding instead of removing material. IMTI has investigated laser consolidation of Fe-, Ni- and Co-base alloys, and the work is underway on Ti-alloys. Laser consolidated (LC) IN-625 is metallurgically sound, free of cracks or porosity. The "as-consoldiated" IN-625 samples has surface finishes of the order of 1-2 *m (Ra) and dimensional accuracy of around 0.05 mm. The tensile properties of the laser-consolidated IN-625 alloy are comparable to the respective wrought materials. The microstructure of the laser-consolidated samples is similar to the rapidly solidified materials. Laser consolidation is a promising process for manufacturing functional net-shape components. The folded shell projector (FSP) is a compact flextensional sound source being developed at DREA for low frequency sonar applications including active towed arrays and sonobuoys. The design radiates from a thin walled cylindrical shell with superimposed corrugations. TRUNCATED
Laser consolidation process;CAM (Computer Aided Manufacturing)
Report Number
DREA-SR-2001-094-SES-V-PAP-26 — Special Report
Date of publication
01 Oct 2001
Number of Pages
Hardcopy;Document Image stored on Optical Disk

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